Kapitel

Winding processes

Industrial research

Service & repairs

Assembly processes

Development processes

Soldering processes

Additive manufacturing

Laser manufacturing

Fine mechanical processes

Protection and embedding

Test and verification processes

Main processes

In the following we have outlined our main processes in a more detailed way to give you a good overview of our company.

Winding processes

As a manufacturer of coiled goods, winding processes are very central to our company. We master all types of winding processes - from classic linear winding to high edge winding, which already goes into bending.

Linear winding technology

With a defined winding, the properties of an inductive component, e.g. efficiency, scattering parameters, damping or dielectric strength, can be strongly influenced. With our know-how, we ensure that an optimal and cost-effective solution is used for your application. We wind mainly copper, partly also aluminum. As semi-finished products we use wire, HF stranded wire, ribbon, flat wire, fine wire up to glass fiber.

Toroidal winding technology

With the help of our toroid winding machines and pull winders, we can wind toroidal cores of all types. When using thick wires or rigid HF strands, toroidal cores can also be wound by hand. Especially in the field of transformer technology, toroidal cores and the corresponding winding technology cannot be replaced. In toroidal machines, the wire is first applied to the magazine and then wound onto the toroid from there.

High-edge winding technology

Our high-cant winding technology gives us an optimum price/performance ratio by maximizing power output in a given space. We can accommodate a lot of power in the smallest possible space. This winding technology provides optimal ventilation and optimal heat dissipation of the winding. It is a simple design because layer insulation can be omitted even with multi-layer winding. The use of flat wire increases the fill factor and leads to minimization of DC losses.

Winding machines

In the field of layer winding, we have a large pool of automatic winding machines. These machines are capable of fully automatically placing simple windings on a coil former and winding the corresponding pins. In discussion with you, we always try to implement the layer structure as automatically as possible in order to keep production costs low.

Industrial research

As a medium-sized company we have to be at the forefront of technology to provide the most innovative, resource saving and cost effective products as possible for our customers. Therefore, we are also very commited in the field of industrial research in parallel to our core business.

Research projects

To be at the forefront regarding know how and to develop innovative ideas, we regularly work with partners from industry and science on publicly funded projects. We are currently part of the research funding LOEWE 3. With the LOEWE 3 program the hessian state government encourages outstanding collaborative scientific projects of universities and research institutions in Hesse. We are also active in other joint projects, such as within the framework of KMU-innovativ or the Central Innovation Program for SMEs (ZIM).

Technician projects

Within the framework of cooperations with several technician schools technician projects take place regularly. Thereby students get the chance to implement a real technical project including the necessary project management in a protected and supervised environment. There are typically four to five team members who get closer to their degree as a technician through these projects. The project contents therefore include an appropriate part of research, which in turn strengthens our company's know how.

Service and repairs

The products of the Pikatron Group agree on high quality and long durability. If nevertheless a defect occurs and a repair needs to be carried out, we will be happy to help. Our service team is looking forward to advise you whether the repair is worthwhile. In the event of a warranty claim, the repair is of course free of charge.

Service

Even after delivery of our components, assemblies, devices and systems, we do not leave you alone: Our service team helps via telephone and video connection, but is also quickly on site with you if the issue cannot be solved remotely. The most common spare parts are in stock, so that we ensure the best system availability. We are also happy to commission our products on site and still adapt the parameterization to the specific conditions.

Repair and maintenance

We repair and maintain our products for you even decades after their delivery. In the process, we replace typical wear parts, take care of cleaning and reconditioning, and - if necessary - carry out intense troubleshooting. We can also carry out comprehensive repairs in the field of motors: Bearing replacement, stator winding, encoder repair, etc. As far as possible, our products are basically designed in such a way that repair is possible in most cases.

Assembly processes

Assembly plays a very central role in our manufacturing operations. As with the production of components, we also carry out the assembly of our assemblies and devices within production lines. In this way, we can offer prices in line with the market and logistics according to your wishes, despite predominantly German locations.

Assembly

We assemble customer-specific assemblies and devices in our production lines. In doing so, we pay attention to the simplest, fastest and safest possible manufacturability during the design stage. At the end of each assembly line there are appropriate testing facilities that ensure the high quality of the products. We assemble both products developed together with you and products that have already been developed and for which you are looking for a production facility.

Switch cabinet construction

We are not classic switch cabinet builders, but we have mastered the 1x1 of switch cabinet construction to perfection. The built up switch cabinets are typically equipped with our devices (e.g. frequency converters) and integrated to a finished parameterized plant. We also create switchgears for e.g. your drive solution for requirement-critical areas such as food technology and EX-protected areas. The planning and documentation takes place by means of PROPLAN.

Development processes

As an innovative medium-sized company, we offer you not only production and logistics but also comprehensive support in the field of power electronics development: Starting from inductive components up to power supplies and equipment. In doing so, we always carry out development with the aim of subsequent production at one of our locations, i.e. we unfortunately do not undertake pure development services.

Development of inductive components

We not only manufacture according to specification, we also provide support in component design. For development and design, our engineers and technicians are available as contact persons for your questions. You decide whether we accompany your development or whether we take over the development for you according to your ideas. We scrutinize your requirements, naturally take into account existing standards, use electrical & magnetic simulations and optimize the design for the desired production quantity.

Development of analogue and digital hardware

The development of analog or digital hardware is one of the core processes in system development. With diverse applications ranging from highly sensitive measurement circuits to microprocessor controls and efficient power electronics, the know-how comes from a single source. Our technicians and engineers ensure that, together with you, a solution is created that meets your requirements and is also economically exciting.

Circuit and layout creation

We have all the necessary tools for the development and design of assemblies, devices and systems. We use modern planning and design systems such as PROPLAN or Eagle. The circuit development for our assemblies and devices is supported by simulation tools such as Maxwell or LTSpice. Layouts are also designed in-house, with attention paid to component availability, EMC criteria and a host of other aspects.

Embedded software development

Besides the hardware, hardware-related software - embedded software - is an essential aspect of our development. We also write this software in-house in ANSI C or assembler, in order to be able to react effectively to your requirements. We use efficient control concepts, network the systems with all common interfaces and protocols and integrate diagnostic functions as standard, which fall into the area of predictive maintenance.

Device concepts and mechanical design

During the design phase, we place great emphasis on a design that is suitable for production and, if possible, allows for constrained guidance during subsequent line production. With our 3D CAD workstations with SolidWorks we generate the data for the later production of all mechanical parts. Here, too, we have competent and experienced employees who can implement your ideas for installation space and size with precision. Of course, we can also provide you with the 3D models for virtual installation in your product.

Design of standard-compliant components, devices and systems

Years of routine in the design of inductive components, coupled with the experience in device development are the prerequisite for a successful result. Compliance with the applicable standards is a matter of course. For the approval at the different certifiers (TÜV, UL, VDE, ...) you receive every support. Due to our breadth of content, we have most likely already become acquainted with your world of standards.

Project planning of drive solutions

With us, you don't get a standard solution, but a package of motor, frequency converter and peripherals that is optimally tailored to your challenge. We configure a complete drive solution that only needs to be installed on site. Benefit from our decades of experience. We use a wide range of synchronous machines, cool-torque motors and asynchronous machines. With our intelligent U-Drive series, a wide range of drives between 1 and 400 kW can be controlled. If required, we will gladly supply the assembled control cabinet.

Customized software and controller adaptation

Whether sequence control, interface adaptation, adaptation of controller parameters, additional safety requirements: We flexibly adapt our software to your needs. In our electronics development, hardware extensions are possible in order to optimally integrate the drive solution into your application. The parameterization of the system (motor and controller characteristics) is also optimally adapted to your application. We are also happy to visit you on site.

Soldering processes

Soldering processes are among the most important contacting and joining processes in our company. We therefore also use all common soldering processes. These include hand soldering, dip soldering, HF soldering and resistance soldering for soft soldering and the soldering flame and also resistance soldering for hard soldering.

Manual soldering

Reliable contacting of the electrical connections is indispensable for the function in an application. Our employees are trained in these important procedures. Specialists trained to IPC A610 and IPC A620 are available at all locations to ensure the quality of solder connections.

Dip soldering

We carry out dip soldering in both manual and automated form. This process is always used when a large number of contacts are to be soldered simultaneously or when, for example, HF strands are to be tinned. We use automatic soldering machines for the production of large quantities.

Resistance soldering and HF soldering

We always use resistance soldering when the solder joints are internal and we cannot get directly to the solder joint with a soldering iron or solder bath. Similarly, we also use partially automated HF soldering. Here, the product to be soldered can be soldered purely inductively without contact.

Additive manufacturing

Additive manufacturing opens up completely new possibilities in many areas of industry. Whether for the rapid creation of samples or the production of small series - it is no longer possible to imagine our product world without it.

3D-print

We are increasingly using additive manufacturing technologies in both development and production. This means shorter product development times (time-to-market), lower costs and prompt provision of prototypes so that requirements can be verified and validated with our customers at an early stage. In addition, a high level of geometric complexity, comprehensive function integration and individual product customization can be implemented. Subsequent changes, which otherwise often entail expensive tooling costs, can now be easily managed.

Laser manufacturing

In addition to the classic precision mechanical manufacturing processes, we use processing lasers for jig and tool making as well as for the production of input materials. In addition to the classic component marking by pad printing, a marking laser is also used more and more frequently.

Laser cutting

With the help of modern laser cutting systems, we achieve consistent precision and quality of the components used from the prototype to the series product while keeping setup and wear costs low. Dimensionally accurate, freely programmable and immediately available contour cuts enable us to economically implement complex individual geometries even for small quantities. Whether for coilformers, housings or tools.

Laser marking

In addition to the classic methods of marking components, assemblies and devices, e.g. by stickers or by pad printing, we also use marking lasers. This allows our products to be permanently marked. Combinations with measuring equipment are also possible, i.e. measurement data is written directly onto the component to simplify further use at your site.

Fine mechanical processes

Fine mechanical processes are indispensable for the production of components, assemblies and devices in the field of power electronics. Therefore, we have a very large know-how in the area of very different precision mechanical processes.

Fine mechanical processes

In addition to the actual winding technology, mechanical processing is also part of a component production. We also manufacture special mu-metal housings specifically for your application. In the area of primary forming processes, we master injection molding; in the area of forming technology, we master punching, bending, turning, milling, drilling, and grinding; and in the area of joining and bonding processes, we master assembly, press-fitting, welding, soldering, and bonding.

Contacting technology

Besides soldering as the most important contacting process, we use many other processes. Some of these are manual processes that require our employees to have extensive qualifications, while others are automated processes that are used primarily for larger quantities. These include crimping, hot crimping, squeezing, pressing, screwing, spot welding and many other processes.

Protection and embedding

Depending on the application, we offer you optimum protection for the components, assemblies and devices: whether in the form of a protective layer, grouting, impregnation or potting. Benefit from decades of experience in the use of these technologies.

Grouting and impregnation

Depending on the application and the vibration, insulation, partial discharge and contamination requirements, we select the appropriate technology during development. We perform potting and vacuum potting of polyurethanes, epoxies, silicones and many other material systems. The impregnation and vacuum impregnation of alkyd resins, polyester-imide resins, epoxies and many other material systems is also part of our scope of services. Of course, we also master the corresponding pre-treatment by e.g. degreasing, sandblasting or plasma activation.

Galvanic processes

We can also ensure the protection of metallic surfaces through an in-house galvanic process. For particularly good conductivity, a long product life and an attractive appearance, a special galvanic coating process is used for copper and brass parts. We have had the know-how for this coating in house since tesch was founded - although at that time it was introduced for the production of high-quality watch movements.

Test and verification processes

To ensure our very high quality in all product areas, the corresponding test and inspection processes are indispensable. This involves both safety-relevant tests and parameter tests that are necessary for the desired function.

100% safety check

Following requirements by standards and directives and in consultation with our customers, we perform a whole range of safety tests on our components, assemblies and equipment to ensure safety, reliability and durability. These include, for example, the following tests: High voltage test up to 30 kV, surge voltage test up to 6 kV, insulation resistance test up to 1 GOhm, protective conductor resistance test, leakage current measurement, temperature test from -70°C to +200°C. All results can also be logged digitally.

Parameter check

To maintain reproducible quality, the electrical values of all our products are characterized during sampling and checked during series production. The measurement conditions are adapted to the respective application conditions and coordinated with our customers. Classical measuring methods: Resistance, inductance, leakage inductance, turns ratio, capacitance, resonant frequency, group delay, ... Small signal parameters: Insertion loss, return loss, ... Measurement in customer application: e.g. sensor calibration (velocity, pressure, magnetic field).

Endurance and performance testing

We carry out an idle test or endurance test for the burn-in for all assemblies and devices in order to reliably detect early failures and pre-material anomalies. We can thus realize high quality without compromise. Of course, we can also apply the load that will occur later in the real application scenario to the test specimen in order to perform a performance test that is as close to reality as possible. The corresponding equivalent loads are co-developed by us parallel to the assembly or device or can be provided by the customer.

Partial discharge test

According to IEC 60270, partial discharges are "local electrical discharges that only partially bridge the insulation between conductors and may or may not occur in the vicinity of a conductor". Partial discharges can, for example, be the result of local electric field strength excesses within the insulation or on the surface of the insulation. To avoid late consequences, we test relevant components for their partial discharge resistance. We can test insertion voltages of up to 15 kV.

Torque and efficiency testing

In the field of drive technology, we can determine performance, heating and efficiency characteristics of existing and newly developed drives on our torque test benches. We can operate motors with nominal torques of up to 10,000 Nm with frequency converters of up to 200 A per phase. Especially when optimizing existing drive concepts, these characterizations are indispensable.

EMC tests

With our EMC measurement technology, we can localize and effectively eliminate interfering radiation and conducted interference. Here we have several network analyzers, measuring receivers and other EMC equipment. The EMC equipment is rounded off by an EMC measurement cabin measuring approx. 5 x 2 meters, which is suitable for preparatory conformity tests (EMC pre-compliance test).